US20080105316A1 - Multiple fluid product stream processing - Google Patents
Multiple fluid product stream processing Download PDFInfo
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- US20080105316A1 US20080105316A1 US11/583,761 US58376106A US2008105316A1 US 20080105316 A1 US20080105316 A1 US 20080105316A1 US 58376106 A US58376106 A US 58376106A US 2008105316 A1 US2008105316 A1 US 2008105316A1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/20—Jet mixers, i.e. mixers using high-speed fluid streams
- B01F25/23—Mixing by intersecting jets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/71—Feed mechanisms
- B01F35/712—Feed mechanisms for feeding fluids
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/71—Feed mechanisms
- B01F35/717—Feed mechanisms characterised by the means for feeding the components to the mixer
- B01F35/7174—Feed mechanisms characterised by the means for feeding the components to the mixer using pistons, plungers or syringes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/71—Feed mechanisms
- B01F35/717—Feed mechanisms characterised by the means for feeding the components to the mixer
- B01F35/7176—Feed mechanisms characterised by the means for feeding the components to the mixer using pumps
- B01F35/717613—Piston pumps
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/8593—Systems
- Y10T137/87571—Multiple inlet with single outlet
- Y10T137/87652—With means to promote mixing or combining of plural fluids
Definitions
- the disclosure relates to fluid processing and, more particularly, to processing of multiple fluid product streams.
- Hydraulic intensifier pumps are used in applications requiring delivery of a high pressure jet of fluid.
- An intensifier pump includes a working barrel, a hydraulic working piston, an intensifier barrel, a product intensifier piston, inlets for a hydraulic working fluid to both advance and retract the piston, an inlet for the product fluid to be pressurized, and an outlet for emission of the pressurized fluid.
- lower pressure hydraulic fluid is applied to the comparatively large diameter working piston.
- the working piston drives the smaller diameter intensifier piston.
- the ratio of the hydraulic and product piston areas is the intensification ratio.
- the hydraulic pressure is multiplied by the intensification ratio to produce an increase in pressure.
- intensifiers can be used for applications in which fluids are mixed, reacted or combined to form coatings, inks, paints, abrasive coatings, fertilizers, pharmaceuticals, biological products, agricultural products, foods, beverages, and the like.
- coatings inks, paints, abrasive coatings, fertilizers, pharmaceuticals, biological products, agricultural products, foods, beverages, and the like.
- the size and uniformity of dispersed phases can be extremely important, and may be impacted by pressure fluctuation.
- the total amount of energy applied to the product fluid is a function of mechanical power, shear, or extensional force, and the time that the product fluid is in the shear or force zone.
- the energy level In order to effectively process dispersions, the energy level must be sufficiently high and uniform to disperse agglomerated structure. Pulsation of fluid flow may produce a gradient between energy levels applied to a dispersion, however, causing a portion of the product to be subjected to insufficient processing energy. Continued processing of the product fluid, under conditions where pulsations exist, is usually inadequate to compensate for the insufficient processing resulting from the energy gradient.
- the disclosure is directed to techniques for processing multiple fluid product streams.
- the techniques employ multiple intensifier pump sub-systems in combination with a multi-stream fluid processing device to mix, react or otherwise combine multiple fluid product streams.
- the intensifier pump sub-systems produce fluid product streams with substantially uniform pressure levels for introduction into the fluid processing device.
- the fluid processing device directs the multiple fluid product streams at one another via opposing flow paths, creating a collision that combines the fluids.
- Supply pumps deliver separate fluid products at intermediate pressure levels.
- Charge intensifier pumps receive the separate fluid products and apply hydraulic intensification to expel the products at higher pressure levels.
- Product intensifier pumps receive the intensified fluid products and expel them at very high pressure levels.
- the supply, charge and product intensifier pumps operate in a coordinated manner to maintain substantially uniform fluid output pressures without significant pressure pulsation.
- the multiple intensifier pump sub-systems may be coupled to deliver the intensified fluid products to a high pressure, multi-stream, annular fluid processing device.
- the annular fluid processing device defines opposing, coaxial, annular flow channels.
- the fluids in the two annular flow channels move in opposite directions, i.e., toward one another, and collide such that the fluids mix, react, or otherwise combine with one another.
- the shear and extensional forces generated by the collision of the fluid annuli can create a smaller, narrower size distribution of dispersed phases.
- the annular fluid processing device supports mixture, reaction or combination of fluids containing one or more dispersed phases such as particulate structures.
- the fluid processing device reduces the size of particles or other units of microstructure in fluid mixtures and combines the mixtures to form dispersions, such as emulsions or suspensions.
- the fluid processing device may be applied to fluids that do not carry dispersed phases, e.g., to form solutions. In either case, the fluid processing device supports combination of two different fluids to form a new combined fluid product.
- the disclosure provides a method comprising intensifying a first fluid via a first intensifier sub-system comprising a first charge intensifier pump, a first product intensifier pump that receives a first fluid from the first charge intensifier pump via a first controllable valve, a second product intensifier pump that receives the first fluid from the first charge intensifier pump via a second controllable valve, intensifying a second fluid via a second intensifier sub-system comprising a second charge intensifier pump, a third product intensifier pump that receives a first fluid from the first charge intensifier pump via a third controllable valve, a fourth product intensifier pump that receives the first fluid from the first charge intensifier pump via a fourth controllable valve, controlling the controllable valves based on positions of pistons associated with the product intensifier pumps such that each of the controllable valves is open when the piston associated with the respective product intensifier pump is near an end of an extension cycle and closed when the piston associated with the respective product intensifier pump is at an end of a retraction
- the disclosure provides a system comprising a first intensifier sub-system comprising a first charge intensifier pump, a first product intensifier pump that receives a first fluid from the first charge intensifier pump via a first controllable valve, a second product intensifier pump that receives the first fluid from the first charge intensifier pump via a second controllable valve, a second intensifier sub-system comprising a second charge intensifier pump, a third product intensifier pump that receives a first fluid from the first charge intensifier pump via a third controllable valve, a fourth product intensifier pump that receives the first fluid from the first charge intensifier pump via a fourth controllable valve, a controller that controls the controllable valves based on positions of pistons associated with the product intensifier pumps such that each of the controllable valves is open when the piston associated with the respective product intensifier pump is near an end of an extension cycle and closed when the piston associated with the respective product intensifier pump is at an end of a retraction cycle, and a fluid processing device having
- FIG. 1 is a block diagram illustrating a multiple fluid product processing system in accordance with an embodiment of this disclosure.
- FIG. 2 is a block diagram illustrating the system of FIG. 1 in greater detail.
- FIG. 3 is a flow diagram illustrating operation of dual charge intensifier pumps in the system of FIGS. 1 and 2 .
- FIG. 4 is a flow diagram illustrating the operation of dual product intensifier sub-systems in the system of FIGS. 1 and 2 .
- FIG. 5 is a cross-sectional diagram of a fluid processing device having an annular fluid flow channel for use with the system of FIGS. 1 and 2 .
- FIG. 1 is a block diagram illustrating a multiple fluid product processing system 10 in accordance with an embodiment of this disclosure.
- system 10 includes dual intensifier sub-systems, each of which pressurizes a different fluid product for combination in a multi-stream fluid processing device.
- system 10 includes a controller 12 , a first fluid supply sub-system 14 A, a second fluid supply sub-system 14 B, and a fluid intensifier system 15 .
- Controller 12 controls the operation of fluid supply sub-systems 14 A, 14 B and fluid intensifier system 15 to produce high pressure streams of fluid for combination in fluid processing device 28 .
- Each fluid sub-system 14 A, 14 B includes a respective fluid reservoir 16 A, 16 B.
- Reservoirs 16 A, 16 B store different fluid products.
- Supply pump 18 A delivers fluid from reservoir 16 A, within one fluid product intensifier sub-system 17 A, formed by reservoir 16 A, supply pump 18 A, charge intensifier 20 A, product intensifier 22 A and product intensifier 24 A.
- Supply pump 18 B delivers fluid from reservoir 16 B to another fluid product intensifier sub-system 17 B, formed by reservoir 16 B, supply pump 18 B, charge intensifier 20 B, product intensifier 22 B, and product intensifier 24 B.
- Controller 12 generates instructions to control the operation of supply pumps 18 A, 18 B.
- Charge intensifier pumps 20 A, 20 B operate as dual charge intensifiers, providing different product fluids at elevated pressures.
- Product intensifier pumps 22 A, 24 A form a first set of dual product intensifiers
- product intensifier pumps 22 B, 24 B form a second set of dual product intensifiers.
- Product intensifiers 22 A, 24 A operate in a coordinated manner, in response to controller 12 , to deliver a high pressure stream of fluid 26 A to fluid processing device 28 .
- product intensifiers 22 B, 24 B operate in a coordinated manner to deliver a high pressure stream of fluid 26 B to fluid processing device 28 .
- Fluid processing device 28 receives the high pressure streams of fluid 26 A, 26 B and combines them.
- fluid processing device 28 may include opposing, annular, coaxial flow paths, each of which carries one of the high pressure streams of fluid 26 A, 26 B.
- the fluid streams 26 A, 26 B collide as the annular flow paths meet, resulting in mixture, reaction, or combination of the fluids.
- system 10 may include various sensors, actuators, controllable valves and check valves to control flow and pressurization of fluid.
- intensifier system 15 gains efficiencies through the use of charge intensifier pumps 20 A, 20 B, which deliver streams of fluid under a relatively high pressure to product intensifier pumps 22 A, 24 A and product intensifier pumps 22 B, 24 B, respectively.
- Each charge intensifier pump 20 A, 20 B functions at a pressure level sufficient to cause a piston in a receiving product intensifier 22 A, 24 A or 22 B, 24 B pump to retract, thus allowing the product intensifier pump barrel to fill with product.
- the respective charge intensifier pump 22 A, 24 A or 22 B, 24 B can continue to increase the pressure within the filled product intensifier pump barrel, thus reducing the amount of preloading required by the product intensifier pump prior to beginning its advance cycle.
- Product intensifier pumps 22 A, 24 A may be configured so that they are at least partially out of phase with one another.
- product intensifier pumps 22 A, 24 A may be controlled by controller 12 so that one is advancing (and hence delivering product) while the other is retracting and preloading.
- the retraction cycles of each set of product intensifier pumps 22 A, 24 A or 22 B, 24 B may at least partially overlap.
- Each one of intensifier sub-systems 17 A, 17 B may conform substantially to the intensifier system described in U.S. Pat. No. 6,558,134, issued May 6, 2003, to Serafin et al., the entire content of which is incorporated herein by reference.
- fluid is allowed to enter product intensifier pump 22 A or 24 A from charge intensifier pump 20 A.
- the fluid is delivered at a relatively high pressure that is sufficient to cause a piston in the product intensifier pump 22 A or 24 A to retract at a relatively high speed.
- the charge intensifier pump 20 A can increase the speed of the retraction stroke of the product intensifier pump 22 A or 24 A.
- the charge intensifier pump 20 A may have a larger product displacement per stroke than that of the product intensifier pumps 22 A, 24 A.
- the charge intensifier pump 20 A fully fills one of the product intensifier pumps 22 A, 24 A with each stroke.
- the charge intensifier pump 20 A fills the product intensifier pumps 22 A, 24 A without introducing air, thus aiding in the control and elimination of pulsation.
- the pistons in product intensifier pumps 22 A, 24 A are retracted quickly with the aid of the charge intensifier pump 20 A.
- the preload period is greatly reduced.
- efficiency is increased through a reduction in the required time duration for each cycle.
- the charge intensifier pump 20 A causes the retraction of each of the product intensifier pumps 22 A, 24 A, there is no need to provide a hydraulic retraction cycle for any of the product intensifier pumps. Rather, in some embodiments, the hardware and fittings necessary for delivery of working fluid for retraction can be eliminated.
- the complexity of the product intensifier pumps 22 A, 24 A is reduced, making them more efficient and cost effective.
- Charge intensifier pump 20 B and product intensifier pumps 22 B, 24 B may operate in a substantially identical manner as that described above with respect to charge intensifier pump 20 A and product intensifier pumps 22 A, 24 A.
- Combining charge intensifier pumps 20 A, 20 B and product intensifier pumps 22 A, 24 A, 22 B, 24 B in parallel enables delivery of multiple fluids to fluid processing device 28 with precise pressure levels.
- the fluid products are delivered, separately, to two independent intermediate intensifier pumps that take advantage of hydraulic intensification to expel the products at high pressures to assure continuous product deployment in various systems.
- the separate products are delivered from the charge intensifier pumps 20 A, 20 B at pressures sufficient to increase the retract speed of the separate, product intensifier pumps 22 A, 24 A, 22 B, 24 B and fill the intensifier barrels with the two different fluids.
- Charge intensifier pumps 20 A, 20 B ensure the filling of the product intensifier barrels without introduction of air.
- charge intensifier pumps 20 A, 20 B produce an elevated pressure in the separate product fluids within the product intensifier pumps 22 A, 24 A, 22 B, 24 B during the end of the retract cycle, thus reducing the amount of preload time required.
- the product intensifiers 22 A, 24 A, 22 B, 24 B subsequently expel the two separate products, simultaneously at very high pressures, e.g., in a range of approximately 5,500 to 40,000 pounds per square inch (psi) (approximately 38 megapascals to 275 megapascals), without significant pressure pulsation.
- psi pounds per square inch
- Controller 12 processes sensor signals indicating the state or position of operation of each charge intensifier pump 20 A, 20 B and product intensifier pump 22 A, 24 A, 22 B, 24 B, and actuates various valves to control the operation of the pumps.
- various sensors can be positioned to allow controller 12 to determine the positions of each of the pistons in the product intensifier pumps 22 A, 24 A, 22 B, 24 B and the charge intensifier pumps 20 A, 20 B.
- Controller 12 actively controls the functioning of a number of valves located throughout the system, which may be referred to herein as “smart” valves.
- a suitable valve is disclosed in U.S. Pat. No. 6,328,542, issued Dec. 11, 2001, to Serafin et al., the entire content of which is incorporated herein by reference.
- Use of a smart valve is also described in the above-referenced '134 patent.
- smart valves are actively controllable valves that can be opened and closed through the use of an actuator that is coupled with the controller 12 .
- the actuator may be an air cylinder, solenoid or other actuating mechanism.
- Controller 12 can determine, based on sensor data, when a particular intensifier pump is at or near the end of an extension or retraction cycle. Controller 12 can then control an actuator to open or close the appropriate smart valve or valves in anticipation of the completion of this cycle.
- FIG. 2 is a block diagram illustrating system 10 of FIG. 1 in greater detail.
- FIG. 2 shows controller 12 , reservoirs 16 A, 16 B, supply pumps 18 A, 18 B, charge intensifier pumps 20 A, 20 B, product intensifier pumps 22 A, 24 A, 22 B, 24 B, and fluid processing device 28 , which may be a multi-stream annulus processor.
- FIG. 2 shows a pump (P 1 ) 27 that delivers hydraulic working fluid to charge intensifier pumps 20 A, 20 B.
- pump 29 delivers hydraulic working fluid to product intensifier pumps 22 A, 24 A
- pump 31 delivers hydraulic working fluid to product intensifier pumps 22 B, 24 B.
- Controller 12 controls the operation of pumps 27 , 29 and 31 .
- Each intensifier pump 20 , 22 , 24 includes a working barrel and an intensifier barrel.
- charge intensifier pump 20 A includes a larger diameter working barrel 33 A with a working piston, and a smaller diameter intensifier barrel 35 A with an intensifier piston.
- the piston 37 A in working barrel 33 A is driven forward by hydraulic fluid.
- the working piston drives the product piston in intensifier barrel 35 A forward to expel product fluid.
- product intensifier pump 24 A includes a larger diameter working barrel 33 C with a piston 37 C that is driven forward by hydraulic fluid.
- the working piston drives the product piston in intensifier barrel 35 C of product intensifier pump 24 A forward to expel product fluid 26 A at an elevated pressure for delivery to fluid processing device 28 .
- Similar arrangements are provided for intensifier pumps 20 B, 22 A, 22 B, 24 B.
- each intensifier pump 20 A, 20 B, 22 A, 24 A, 22 B, 24 B also includes a sensor (S) 36 A- 36 F.
- Each sensor 36 may be formed by a linear position transducer (LPT), linear variable displacement transducer (LVDT), limit switch, proximity switch, or other sensor capable of provide an indication of the position of the working piston to controller 12 .
- system 10 also includes a set of actuators (A) 32 A- 32 F and smart valves (SV) 30 A- 30 F. Actuators 32 open and close respective smart valves 30 , in response to control signals from controller 12 , to control flow of product fluid into the intensifier barrels of the respective intensifier pumps 20 , 22 , 24 .
- product intensifier pumps 22 A, 24 A, 22 B, 24 B each include a respective check valve (CV) 34 A- 34 D between the output of the intensifier product barrel and fluid processing device 28 .
- CV 34 A- 34 D is a passive one-way valve that prevents backflow into one pump (e.g., 22 A) when the other pump (e.g., 22 B) in the pair is expelling fluid at high pressure.
- Controller 12 receives sensor signals (S 1 -S 6 ) from sensors 36 A- 36 F, as indicated by block 36 in FIG. 2 .
- controller 12 In response to the sensor signals, controller 12 generates control signals (A 1 -A 6 ) to control actuators 32 A- 32 B and thereby control the operation of intensifier pumps 20 , 22 , 24 , as indicated by block 32 . In particular, controller 12 controls the timing during which product fluid is introduced into the intensifier barrels of the intensifier pumps 20 , 22 , 24 .
- Reservoirs 16 A, 16 B store different fluid products, such as any combination of dissimilar liquids and/or liquid/solid mixtures, including chemicals, dispersions, solvents, emulsions and liposomes.
- the fluids in reservoirs 16 A, 16 B may have different solid contents, agglomerations, and different types of dispersed phases, such as hard particles.
- at least one of the fluids in reservoirs 16 A, 16 B may be an aqueous solution.
- fluids from reservoirs 16 A, 16 B enter the intensifying system via supply pumps 18 A, 18 B, respectively.
- Each supply pump 18 A, 18 B may be a diaphragm pump capable of delivering fluid at approximately 60-100 psi (approximately 0.4 megapascals to 0.7 megapascals). This pressure may be varied from application to application depending on system design and the types of fluid carried.
- Supply pump 18 A feeds the first fluid product from reservoir 16 A to smart valve 30 A, which functions as a controllable check valve that can be actively opened and closed by an actuator 32 A, under control by controller 12 , as described above.
- Smart valves 30 A- 30 F, actuators 32 A- 32 F, sensors 36 A- 36 F, pumps 27 , 29 , 31 , and controller 12 collectively form a control system for fluid processing system 10 .
- Smart valve 30 A controls flow of product fluid into the intensifier barrel of charge intensifier pump 20 A. When smart valve 30 A is opened, the product fluid from supply pump 18 A is allowed to fill the intensifier barrel 35 A of charge intensifier pump 20 A. When smart valve 30 A is closed, the product fluid cannot enter intensifier barrel 35 A.
- a piston within charge intensifier pump 30 A advances under hydraulic pressure produced by pump 27 , expelling the product fluid at an intermediate pressure, e.g., in the range of approximately 700-2000 psi (approximately 4.8 megapascals to 13.8 megapascals).
- hydraulic fluid provided by pump 27 fills the working barrel 33 A and drive the piston forward in the intensifier barrel 35 A to expel the product fluid.
- smart valve 30 A is closed and functions as a check valve to prevent backflow of product fluid toward supply pump 18 A.
- the product fluid is transmitted to smart valves 30 C, 30 D for introduction into the product barrels 35 C, 35 D of product intensifier pumps 24 A, 22 A, respectively.
- charge intensifier pump 18 B may function in similar way.
- charge intensifier pump 18 B receives product fluid in intensifier barrel 35 B from supply pump 18 B when controller 12 controls actuator 32 B to open smart valve 30 B. Hydraulic fluid introduced into working barrel 33 B by pump 27 drives the piston 37 B forward to expel the product fluid out of intensifier barrel 35 B at an increased pressure.
- charge intensifier pump 20 B transmits the resulting product fluid to a pair of product intensifier pumps, in this case product intensifier pumps 22 B, 24 B via smart valves 30 F, 30 E, respectively.
- the product fluid arriving at the respective product intensifier pumps 22 A, 24 A and 22 B, 24 B arrive at a substantially increased pressure relative to the pressure provided by supply pumps 18 A, 18 B due to the additional pressurization provided by a respective charge intensifier pump 20 A, 20 B.
- the pressurized fluid e.g., in a range of approximately 700-2000 psi (approximately 4.8 megapascals to 13.8 megapascals), passes through the open smart valve 30 and has sufficient force to retract the piston in the product intensifier barrel 35 at a relatively high speed and subsequently fully fill the product intensifier barrel.
- the charge intensifier pump 20 A, 20 B fills the intensifier barrel 35 of the respective product intensifier pump 22 , 24 without introducing air into the barrel.
- the charge intensifier pump 20 continues to deliver pressurized product fluid to the intensifier barrel 35 , the product fluid is effectively preloaded.
- the respective smart valve 30 is closed by actuator 32 , under control by controller 12 , preventing backflow of product fluid.
- Controller 12 determines whether to open and close the various smart valves 30 based on the positions of the respective pistons 37 A- 37 F of the associated intensifier pumps 20 , 22 , 24 .
- Sensors 36 A- 36 F may be placed at the ends of the hydraulic pistons in charge intensifier pumps 20 A, 20 B and product intensifier pumps 22 A, 24 A, 22 B, 24 B,.or elsewhere, to sense the positions of the pistons and transmit the information to controller 12 .
- charge intensifier pump 20 A for example, when the respective piston is at or near the end of a retraction cycle, controller 12 closes smart valve 30 A to stop the fluid flow from supply pump 18 A to the charge intensifier barrel 35 A.
- controller 12 controls hydraulic pump 27 to pump hydraulic fluid to working barrel 33 A under pressure to drive the piston forward within intensifier barrel 35 A and thereby expel the fluid to one of the product intensifier pumps 22 A, 24 A.
- Product intensifier pumps 22 A, 24 A operate at least partially out of phase to receive product fluid at different times.
- the piston 37 D in first product intensifier pump 22 A is generally in a retracted position when the piston 37 C in second product intensifier pump 24 A is at or near the end of an extension cycle.
- the-piston 37 D in product intensifier pump 22 A is in an extended position when the piston 37 C in product intensifier pump 24 A is in a retracted position.
- the retraction cycles of each pair of product intensifier pumps 22 A, 24 A or 22 B, 24 B may overlap for a limited period of time.
- Product intensifier pumps 22 B, 24 B operate in a similar manner, providing out-of-phase intensification of product fluid received from charge intensifier pump 20 B. In this way, each pump in a respective pair of product intensifiers pumps 22 A, 24 A or 22 B, 24 B operates out of phase with the other pump in the pair to provide a combined output that is substantially continuous and constant.
- Product intensifier pumps 22 A, 24 A receive hydraulic working fluid within working barrels 33 D, 33 C from pump 29 , while product intensifier pumps 22 B, 24 B receiving hydraulic working barrels 33 F, 33 E from pump 31 .
- Controller 12 controls the operation of pumps 27 , 29 , and 31 in response to sensor signals received from sensors 36 A- 36 F, and also control actuators 32 A- 32 F in coordination with pumps 27 , 29 , and 31 to control the opening and closing of smart valves 30 A- 30 F.
- Product intensifier pumps 22 A, 24 A, 22 B, 24 B may include substantially the same components as those of charge intensifier pumps 20 A, 20 B.
- each product intensifier pump 22 A, 24 A, 22 B, 24 B includes a respective piston 37 C- 37 F that includes working surfaces within working barrel 33 C- 33 F and intensifier barrel 35 C- 35 F.
- hydraulic fluid injected into working barrel 33 C- 33 F drives the working surface of the piston forward to expel fluid from intensifier barrel 35 C- 35 F during an advance cycle.
- injection of product fluid into intensifier barrel 35 C- 35 F drives the working surface of the piston backwards during a retraction cycle.
- Each piston 37 C- 37 F is described as a unitary piston having surfaces in the working barrel 33 C- 33 F and intensifier barrel 35 C- 35 F. In some embodiments, however, each piston may include a working piston in working barrel 33 C- 33 F and a separate intensifier piston in intensifier barrel 35 A- 35 F, and the working and intensifier pistons may be coupled together, e.g., by a rod or other coupling member.
- a sensor 36 C- 36 F is mounted with each product intensifier pump 22 A, 24 A, 22 B, 24 B to sense the position of the piston 37 C- 37 F within the working barrel 33 C- 33 F and/or intensifier barrel 35 C- 35 F, and transmit the sensed position to controller 12 .
- each sensor 36 may be formed by a linear position transducer (LPT), linear variable displacement transducer (LVDT), limit switch, proximity switch, or other sensor capable of providing an indication of the position of the piston to controller 12 .
- Controller 12 uses the position information to actuate various smart valves 30 C- 30 F via actuators 32 C- 32 F and control pumps 29 , 30 , 31 , and thereby allow the pressurized product fluid to flow from the appropriate charge intensifier pump 20 A, 20 B to the appropriate product intensifier pump 22 A, 24 A, 22 B, 24 B.
- controller 12 delays the advance cycle for a short period of time to permit preloading of the piston 37 C. Controller 12 then activates pump 29 to inject hydraulic working fluid into working barrel 33 C to drive piston 37 C forward. At the same time, controller 12 closes smart valve 30 C. As piston 37 C advances within intensifier barrel 35 C, fluid is expelled through one-way check valve (CV) 34 A and into fluid processing device 28 .
- CV check valve
- controller 12 While piston 37 C of product intensifier pump 24 A is advancing, controller 12 actuates smart valve 30 D so that intensifier barrel 35 D of product intensifier pump 22 A is filled with product fluid from charge intensifier pump 20 A, thereby retracting piston 37 D. Because the fluid is delivered at high pressure, e.g., at approximately 800-1200 psi, piston 37 D is forced to retract backward at a relatively high speed, eliminating the need to provide a mechanism to hydraulically retract the piston.
- controller 12 closes smart valve 30 D and injects hydraulic working fluid into working barrel 33 D to drive piston 37 D forward and thereby expel product fluid from intensifier barrel 35 D at a high pressure.
- the high pressure product fluid flows through check value 34 B to fluid processing device 28 .
- Check valve 34 A transmits flow in only one direction, toward fluid processing device 28 , preventing backflow of pressurized fluid into product intensifier pump 24 A.
- Charge intensifiers 20 A, 20 B may be constructed to have a larger product displacement per stroke than that of product intensifiers 22 A, 24 A, 22 B, 24 B. Therefore, charge intensifiers 20 A, 20 B may be capable of fully filling intensifier barrels 37 C- 37 F with each respective advance stroke. In addition, charge intensifiers 20 A, 20 B fill intensifier barrels 37 C- 37 F without introducing air, thus aiding in the control and elimination of pulsation in the output flow.
- controller 12 may be configured so that it does not immediately close smart valve 30 D upon full retraction of piston 37 D of intensifier pump 22 A. Likewise, controller 12 may operate in the same way for intensifier pumps 24 A, 22 B, and 24 B. Instead of immediately closing respective smart valves 30 C- 30 F upon full retraction, controller 12 may allow the smart valves to remain open for a period of time to permit continued preloading. As the fluid continues to be delivered by charge intensifier 20 A or 20 B, the pressure within the respective product intensifier barrel 35 C- 35 F continues to increase, e.g., to approximately 1600-1700 psi (approximately 11.0 to 11.7 megapascals).
- controller 12 then closes the respective smart valve 30 C- 30 D to shut off the fluid supply, and prevent any backflow. Also, at about the same time that the smart valve is closed, controller 12 activates pump 29 or 31 , as applicable, to supply hydraulic working fluid to the respective product intensifier pump 22 A, 24 A, 22 B, 24 B, causing the respective piston 37 C- 37 F to advance.
- charge intensifier pump 20 A is supplying fluid to the first pair of product intensifier pumps 22 A, 24 A, and those pumps are operating out-of-phase with one another to deliver highly pressurized product fluid to fluid processing device 28
- charge intensifier pump 20 B and the second pair of product intensifier pumps 22 B, 24 B are operating in the same manner.
- the intensifier sub-system formed by charge intensifier pump 20 A, product intensifier pump 22 A, and product intensifier pump 24 A delivers a different fluid than the intensifier sub-system formed by charge intensifier pump 20 B, product intensifier pump 22 B, and product intensifier pump 24 B.
- system 10 supports supply of two different fluids to fluid processing device 28 for mixing, reacting, combining, or other processing of the fluids.
- system 10 may include additional intensifier sub-systems similar or identical to those shown in FIG. 2 to deliver additional fluids such that the system can support processing of two or more fluids. In each manner, consistent delivery of multiple intensified product fluids can be achieved to support a variety of multiple fluid product stream applications.
- Controller 12 may be formed by a single centralized controller, or a plurality of parallel or distributed controllers.
- each intensifier pump may include its own controller, linked to a respective sensor and smart valve.
- a single controller 12 may be desirable.
- Controller 12 may be realized by any combination of one or more microprocessors, microcontrollers, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or the like, and may include hardware, software, firmware, or any combination of such components.
- ASICs application specific integrated circuits
- FPGAs field programmable gate arrays
- Controller 12 controls smart valves 30 A- 30 C and pumps 27 , 29 , 31 in response to piston position signals provided by sensors 36 A- 36 F to ensure precise and coordinated operation of the various intensifier pumps.
- controller 12 also may receive sensed pressure levels from pressure sensors placed in various flow lines throughout system 10 .
- the pressure of the intensified fluids in the output lines leading to fluid processing device 28 may be in a range of approximately 5,500 to 40,000 psi (approximately 38 megapascals to 275 megapascals).
- the fluid Upon exiting fluid processing device 28 , the fluid is then delivered downstream to be utilized in any appropriate process. For example, in the case of magnetic particle dispersions, the resulting fluid may be used to coat disk or tape media.
- Pump 27 may be selected to have sufficient power to inject hydraulic fluid into both charge intensifier pump 20 A and charge intensifier pump 20 B at substantially the same time. In this manner, charge intensifier pumps 20 A, 20 B may advance and retract simultaneously to deliver pressurized product fluid at substantially the same time.
- charge intensifier pumps 20 A, 20 B may operate out of phase with one another, such that one intensifier pump 20 A, 20 B advances while the other intensifier pump retracts or is in a retracted position.
- additional valve hardware may be added to selectively fill with working barrels 33 A, 33 B of one of the charge intensifier pumps 20 A, 20 B at a given time. In many applications, however, simultaneous deliver of fluid by charge intensifier pumps 20 A, 20 B may be desirable, either by using a common pump 27 or two pumps operating in unison.
- Pumps 29 , 31 deliver sufficiently pressurized hydraulic fluid to advance first product intensifier pumps 22 A, 24 A and second product intensifier pumps 22 B, 24 B, respectively, on a time cycle that the advance and retract cycles of the pumps in each pair is either completely or partially out of phase with one another.
- product intensifier pump 22 A retracts and preloads
- product intensifier pump 24 A advances, and vice versa, in response to fluid delivered by pump 29 and selective actuation of smart valves 30 C, 30 D.
- product intensifier pump 22 B retracts and preloads
- product intensifier pump 24 B advances, and vice versa, in response to fluid delivered by pump 31 and selective actuation of smart valves 30 E, 30 F.
- product intensifier pump 22 A When product intensifier pump 22 A operates partially out of phase with product intensifier pump 24 A, there also may be a slight overlap in the advancing cycle such that that is there is a short period in which both product intensifier pumps 22 A, 24 A are in the advancing cycle. For example, when the product intensifier pump 24 A is near the end of the advancing phase or is almost fully extended, product intensifier pump 22 A has already started to begin its advancing phase. This overlapping operation assures a consistent and uniform material output.
- multiple hydraulic fluid pumps may be used to supply hydraulic fluid to each pair of product intensifier pumps 22 A, 24 A and 22 B, 24 B. However, a single pump for each pump 22 A, 24 A or 22 B, 24 B may be preferred.
- pumps 27 , 29 , 31 may be powered by a single, common electric motor. With the same single motor and single power source, pumps 27 , 29 , 31 may operate consistently without significant variation in energy/power fluctuation from pump to pump. Therefore, whether the system is used as a delivery system of multiple fluid streams or as a mixing system utilizing its high pressure and high velocity product outputs, the use of the single motor to power the hydraulic fluid pumps 27 , 29 , 31 contributes to substantially pulse-free operation.
- FIG. 3 is a flow diagram illustrating operation of dual charge intensifier pumps 20 A, 20 B in the system 10 of FIGS. 1 and 2 .
- controller 12 engages supply pump 18 A ( 42 A) and supply pump 18 B ( 42 B) to deliver product fluid to charge intensifier pumps 20 A, 20 B, respectively.
- Controller senses the positions of the pistons in charge intensifier pumps 20 A, 20 B ( 43 A, 43 B) via the various position sensors 36 A, 36 B.
- controller 12 closes the associated smart valve 30 A, 30 B ( 44 A, 44 B), and applies the hydraulic fluid pump 27 to advance the piston in respective charge intensifier pump ( 46 A, 46 B). As the piston advances, the respective charge intensifier pump 20 A, 2 B delivers intensified fluid ( 48 A, 48 B).
- controller 12 opens the pertinent smart valve 30 A, 30 B ( 52 A, 52 B) to allow the respective supply pump 18 A, 18 B to deliver product fluid to the intensifier barrel 35 A, 35 B or the respective charge intensifier pump 20 A, 20 B and thereby retract the intensifier piston ( 54 A, 54 B), thereby filling the intensifier barrel ( 56 A, 56 B). If the piston is not full retracted or fully extended, controller 12 waits for a delay period ( 50 A, 50 B) to receive the next position indication from sensors 36 A, 36 B. Position signals may be provided by sensors 36 A, 36 B on a continuous, periodic basis, or only when the piston reaches a predetermined position. The actuation of smart valves 30 A, 30 B and activation of pump 27 may be controlled on a coordinated or independent basis by controller 12 .
- FIG. 4 is a flow diagram illustrating the operation of dual product intensifier sub-systems in the system 10 of FIGS. 1 and 2 .
- controller senses the positions of pistons associated with product intensifier pump 22 A, 24 A, 22 B, 24 B ( 60 A, 74 A, 60 B, 74 B, respectively) via respective sensors 36 C- 36 F.
- controller 12 opens a respective smart valve ( 62 A, 76 A, 62 B, 76 B), allowing the piston in the product intensifier pump to receive intensified product fluid from charge intensifier pump 20 A or 20 B, and thereby retract ( 64 A, 78 A, 64 B, 78 B).
- fully extended means that the piston is at or near the end of its advance cycle. This includes positions just prior to completing a full advance stroke, completing the full advance stroke, and the initial period of retraction just after completing a full advance stroke. The exact position at which the sensor will indicate that the piston is fully extended will depend upon the desired operating parameters of the system.
- controller 12 When controller 12 senses that the piston in a respective product intensifier pump 22 A, 24 A, 22 B, 24 B is retracted, the controller waits to a delay period so that the piston remains retracted for a short period of time to support pre-loading ( 66 A, 80 A, 66 B, 80 B).
- the controller waits to a delay period so that the piston remains retracted for a short period of time to support pre-loading ( 66 A, 80 A, 66 B, 80 B).
- the respective charge intensifier pump 20 A, 20 B continues to deliver material to the respective product intensifier pump 22 A, 24 A, 22 B, 24 B, the pressure within the respective intensifier barrel 35 C- 35 F increases, providing pre-loading.
- smart valves 30 C- 30 F remains open until a predetermined pressure is measured, rather than waiting for a predetermined delay period.
- Controller 12 then controls pump 29 or 31 , as applicable, to deliver hydraulic fluid to the respective working barrel 33 C- 33 F, and thereby advances the piston to a preload position ( 68 A, 82 A, 68 B, 82 B).
- the piston then enters an extension cycle ( 70 A, 84 A, 70 B, 84 B) to advance the piston and thereby expel the intensified product fluid ( 72 A, 86 A, 72 B, 86 B) for delivery to fluid processing device 28 .
- Charge intensifier pumps 22 A, 24 A generally perform the same functions, but at different times so that the two product intensifier pistons work together to achieve a smooth and continuous product outflow.
- Charge intensifier pumps 22 B, 24 B work in a similar manner. The process continues indefinitely under control of controller 12 until a desired amount of the two or more fluids has been delivered to fluid processing device 28 .
- FIG. 5 is a cross-sectional diagram of a fluid processing device 28 having an annular fluid flow channel for use with the system 10 of FIGS. 1 and 2 .
- the fluid processing device 28 of FIG. 5 is an example of a multiple fluid product stream processing device suitable for use with system 10 .
- Fluid processing device 28 may be similar to the device described in U.S. Pat. No. 6,923,213, the entire content of which is incorporated in this disclosure by reference.
- Fluid processing device 28 may be designed to handle pressurized fluids from intensifier system 10 , at a pressure up to or greater than approximately 40,000 psi (275 MPa).
- the first fluid from system 10 enters processing device 28 through first input 26 A, and the second fluid from system 10 enters the device through second input 26 B.
- the first fluid is contained within flow channel 100 while the second fluid is contained within flow channel 102 .
- Flow channels 100 , 102 feed into opposing annular flow channels 104 , 106 , respectively, of a flow path cylinder 108 , which defines an annular flow channel for the first and second fluids.
- the inner diameter of flow path cylinder 108 defines an outer diameter of annular flow channels 104 , 106 that feed toward one another to meet at the center of cylinder 108 .
- Rod 110 is positioned inside flow path cylinder 108 , and defines first and second ends. A first end of rod 110 extends into annular flow channel 104 and a second end of rod 110 extends into second annular flow channel 106 .
- rod 110 may be concentric with the annular flow channels 104 , 106 , having a center axis that is aligned with the central longitudinal axis of flow path cylinder 108 .
- the outer diameter of rod 110 defines the inner diameter of annular flow channels 104 , 106 . Accordingly, flow channels 100 and 102 respectively feed into annular flow channels 104 and 106 defined by flow path cylinder 108 and rod 110 .
- the various flow paths and channels within device 28 may be machined using a common block of material.
- the first fluid flows along annular flow channel 104 , e.g., from left to right in FIG. 5
- the second fluid flows along annular flow channel 106 , e.g., from right to left in FIG. 5 .
- the two fluids collide at or near outlet 112 formed in flow path cylinder 108 , e.g., approximately at the lateral center of cylinder 108 .
- Outlet 112 is ported through the wall of cylinder 108 at the midpoint along the length of the cylinder.
- the energy dissipation from the shear and extensional forces of the collision of the two fluids flowing along annular flow channels 104 and 106 causes a reduction in size of the dispersed phase or phases. For example, agglomerations in each fluid can be broken up into smaller sized particles.
- first fluid and the second fluid are mixed, reacted or combined to form a newly combined final fluid product.
- annular flow channels 104 and 106 may enhance wall shear forces in fluid processing device 28 by increasing surface area associated with flow channels 104 and 106 .
- fluid processing device 28 may be used to reduce the size dispersed phase, such as particles, in each of the two fluids.
- the final fluid product is expelled through outlet 112 and exits fluid processing device 28 via an output line.
- high pressure fluid may be heated through a heater or cooled down from the intensifying process within intensifier system 10 by a heat exchanger (not shown) prior to entering processing device 28 .
- Fluid processing device 28 may include pressure sensors 114 and 118 to measure the pressure of each fluid within fluid processing device 28 , as well as temperature sensors 116 and 120 to measure the input temperatures of the first and second fluids. In a chemical reaction case, for example, another temperature sensor at output 112 may also be included (not shown).
- Sensors 116 and 120 may comprise thermocouples, thermistors, or the like. In some embodiments, temperature sensors 116 and 120 may be located at different positions within fluid processing device 28 .
- Controller 12 may receive the pressure measurement and adjust the pressure of the fluids at first and second inputs 26 A, 26 B via one or more regulator valves to maintain a desired pressure within fluid processing device 28 .
- the controller may adjust the pressure of charge intensifier pumps 20 A, 20 B and/or both product intensifiers 22 A, 24 A and 22 B, 24 B.
- the controller 12 may receive temperature measurements, and cause adjustment of the temperature to one or more fluids, as needed, by changing the heater and/or heat exchanger settings to maintain a desired input temperature for each fluid entering the fluid processing device 28 in response to a desired output temperature at output 112 .
- Substantially identical flows of each fluid down their respective annular flow channels 102 , 104 are indicative of a non-clogged condition.
- Temperature monitoring in particular, may be used to identify when a clogged condition occurs, and may be used to identify when anti-clogging measures should be taken, e.g., by application of a pulsated short term pressure increase in one or both input flows to clear the clog.
- controller 12 may sense parameters such as temperature or pressure and control the pressure of the fluids delivered into the annular flow channels 104 , 106 to unclog the flow channels.
- Gland nuts 122 and 124 may be used to secure flow path cylinder 108 in the proper location within fluid processing device 28 .
- Gland nuts 122 and 124 may be formed with channels (indicated by dotted lines in FIG. 5 ) that allow fluid to flow freely through flow channels 100 , 102 and into annular flow channels 104 , 106 , respectively.
- Rod 110 may be cylindrically shaped, although the disclosure is not necessarily limited in that respect. For example, other shapes of rod 110 may further enhance wall shear forces in the annular flow channels. Alternative shapes may include a circular cylinder, oval cylinder or polygon cylinder.
- Rod 110 may be free to move and vibrate within the flow path cylinder 108 .
- rod 110 may be unsupported within flow path cylinder 108 . Free movement of rod 110 relative to flow path cylinder 108 may provide an automatic anti-clogging action to fluid processing device 28 . If dispersed phase, such as particles or agglomerations, in one or both of the fluids become clogged inside fluid processing device 28 , e.g., at the edges of annular flow channels 104 or 106 , rod 110 may respond to local pressure imbalances by moving or vibrating.
- a clog within cylinder 110 or in proximity of annular flow channels 104 or 106 may result in a local pressure imbalance that causes rod 110 to move or vibrate.
- the movement and/or vibration of rod 110 may help to clear the clog and return the pressure balance within fluid processing device 28 .
- rod 110 may be fixed within fluid processing device 37 .
- rod 110 may be supported by struts, bearings, or the like.
- a pulsated short term pressure increase in the input flow at first input 26 A, second input 26 B or both can be performed upon identifying a clog.
- temperature sensors 116 , 120 , and a temperature sensor (not shown) at output 112 may identify temperature changes in flow channels 100 , 102 , which may be indicative of a clogged condition.
- controller 12 may control pumps or smart valves in system 10 to apply a short term pressure increase, e.g., a two-fold pressure increase for approximately a five-second duration, which may cause more substantial movement and/or vibration of rod 110 to facilitate clog removal.
- the pulsated short term pressure increase in one or both input flows may be performed in response to identifying a clogged condition, or on a periodic basis.
- product intensifier pumps 22 A, 24 A, 22 B, 24 B and/or both charge intensifier pumps 20 A, 20 B may be controlled by controller 12 to adjust the input pressure of the respective first or second fluids to fluid processing device 28 .
- controller 12 may control inlet valves associated with device 28 the first and second fluids to selectively increase or decrease pressure and thereby unclog device 28 .
- a short term pressure increase may be particularly useful in clearing clogs that affect both annular flow channels 104 and 106 In that case, the temperature of both input flow paths may be similar, but may increase because of the clog that affects both annular flow channels 104 , 106 .
- outlet 112 may have a fixed or adjustable size.
- outlet 112 may take the form of a gap with an adjustable width.
- Flow path cylinder 108 and rod 110 may define substantially constant diameters.
- the components of fluid processing device 28 including flow path cylinder 108 and rod 110 may be formed of a hard durable metallic material such as steel or a carbide material.
- flow path cylinder 108 and rod 110 may be formed of tungsten carbide containing approximately six percent tungsten by weight;
- an intensifier and processing system designed to accommodate two different fluid products
- the system may be adapted for multiple product streams, e.g., two, three or more fluid products.
- an intensifier sub-system as described herein may be replicated to provide an additional fluid product stream into a fluid processing device.
- two, three or more different product fluids may be directed at one another to achieve mixing, reaction, or combination of the fluids.
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Abstract
The disclosure is directed to techniques for processing multiple fluid product streams. The techniques employ multiple intensifier pump systems in combination with a fluid processing device to mix, react or otherwise combine multiple fluid product streams. The intensifier pump systems produce fluid product streams with substantially uniform pressure levels for introduction into the fluid processing device. The fluid processing device directs the multiple fluid product streams at one another via opposing flow paths, providing a dispersed phase. The intensifier pump systems include supply pumps that deliver separate fluid products at intermediate pressure levels. Charge intensifier pumps receive the separate fluid products and apply hydraulic intensification to expel the products at high pressure levels. Product intensifier pumps receive the intensified fluid products and expel them at high pressures. The supply, charge and product intensifier pumps operate in a coordinated manner to maintain a substantially uniform fluid pressures without significant pulsation.
Description
- The disclosure relates to fluid processing and, more particularly, to processing of multiple fluid product streams.
- Hydraulic intensifier pumps are used in applications requiring delivery of a high pressure jet of fluid. An intensifier pump includes a working barrel, a hydraulic working piston, an intensifier barrel, a product intensifier piston, inlets for a hydraulic working fluid to both advance and retract the piston, an inlet for the product fluid to be pressurized, and an outlet for emission of the pressurized fluid. In operation, lower pressure hydraulic fluid is applied to the comparatively large diameter working piston. The working piston, in turn, drives the smaller diameter intensifier piston. The ratio of the hydraulic and product piston areas is the intensification ratio. The hydraulic pressure is multiplied by the intensification ratio to produce an increase in pressure.
- Uniform pressure in an intensifier system can be a problem, particularly for industrial applications involving the mixing, reaction or combination of fluids to form emulsions, suspensions or solutions. As examples, intensifiers may be used for applications in which fluids are mixed, reacted or combined to form coatings, inks, paints, abrasive coatings, fertilizers, pharmaceuticals, biological products, agricultural products, foods, beverages, and the like. For some of these products, the size and uniformity of dispersed phases can be extremely important, and may be impacted by pressure fluctuation.
- The total amount of energy applied to the product fluid is a function of mechanical power, shear, or extensional force, and the time that the product fluid is in the shear or force zone. In order to effectively process dispersions, the energy level must be sufficiently high and uniform to disperse agglomerated structure. Pulsation of fluid flow may produce a gradient between energy levels applied to a dispersion, however, causing a portion of the product to be subjected to insufficient processing energy. Continued processing of the product fluid, under conditions where pulsations exist, is usually inadequate to compensate for the insufficient processing resulting from the energy gradient.
- The disclosure is directed to techniques for processing multiple fluid product streams. The techniques employ multiple intensifier pump sub-systems in combination with a multi-stream fluid processing device to mix, react or otherwise combine multiple fluid product streams. The intensifier pump sub-systems produce fluid product streams with substantially uniform pressure levels for introduction into the fluid processing device. The fluid processing device directs the multiple fluid product streams at one another via opposing flow paths, creating a collision that combines the fluids.
- Supply pumps deliver separate fluid products at intermediate pressure levels. Charge intensifier pumps receive the separate fluid products and apply hydraulic intensification to expel the products at higher pressure levels. Product intensifier pumps receive the intensified fluid products and expel them at very high pressure levels. The supply, charge and product intensifier pumps operate in a coordinated manner to maintain substantially uniform fluid output pressures without significant pressure pulsation.
- The multiple intensifier pump sub-systems may be coupled to deliver the intensified fluid products to a high pressure, multi-stream, annular fluid processing device. The annular fluid processing device defines opposing, coaxial, annular flow channels. The fluids in the two annular flow channels move in opposite directions, i.e., toward one another, and collide such that the fluids mix, react, or otherwise combine with one another. When applied to a dispersion, the shear and extensional forces generated by the collision of the fluid annuli can create a smaller, narrower size distribution of dispersed phases.
- The annular fluid processing device supports mixture, reaction or combination of fluids containing one or more dispersed phases such as particulate structures. The fluid processing device reduces the size of particles or other units of microstructure in fluid mixtures and combines the mixtures to form dispersions, such as emulsions or suspensions. Alternatively, the fluid processing device may be applied to fluids that do not carry dispersed phases, e.g., to form solutions. In either case, the fluid processing device supports combination of two different fluids to form a new combined fluid product.
- In one embodiment, the disclosure provides a method comprising intensifying a first fluid via a first intensifier sub-system comprising a first charge intensifier pump, a first product intensifier pump that receives a first fluid from the first charge intensifier pump via a first controllable valve, a second product intensifier pump that receives the first fluid from the first charge intensifier pump via a second controllable valve, intensifying a second fluid via a second intensifier sub-system comprising a second charge intensifier pump, a third product intensifier pump that receives a first fluid from the first charge intensifier pump via a third controllable valve, a fourth product intensifier pump that receives the first fluid from the first charge intensifier pump via a fourth controllable valve, controlling the controllable valves based on positions of pistons associated with the product intensifier pumps such that each of the controllable valves is open when the piston associated with the respective product intensifier pump is near an end of an extension cycle and closed when the piston associated with the respective product intensifier pump is at an end of a retraction cycle, and processing the first and second fluids in a fluid processing device having a first input that receives the first fluid from the first and second product intensifier pumps, a second input receives the second fluid from the third and fourth product intensifier pumps, and an output that delivers a combined product of the first and second fluids.
- In another embodiment, the disclosure provides a system comprising a first intensifier sub-system comprising a first charge intensifier pump, a first product intensifier pump that receives a first fluid from the first charge intensifier pump via a first controllable valve, a second product intensifier pump that receives the first fluid from the first charge intensifier pump via a second controllable valve, a second intensifier sub-system comprising a second charge intensifier pump, a third product intensifier pump that receives a first fluid from the first charge intensifier pump via a third controllable valve, a fourth product intensifier pump that receives the first fluid from the first charge intensifier pump via a fourth controllable valve, a controller that controls the controllable valves based on positions of pistons associated with the product intensifier pumps such that each of the controllable valves is open when the piston associated with the respective product intensifier pump is near an end of an extension cycle and closed when the piston associated with the respective product intensifier pump is at an end of a retraction cycle, and a fluid processing device having a first input that receives the first fluid from the first and second product intensifier pumps, a second input receives the second fluid from the third and fourth product intensifier pumps, and an output that delivers a combined product of the first and second fluids.
- The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
-
FIG. 1 is a block diagram illustrating a multiple fluid product processing system in accordance with an embodiment of this disclosure. -
FIG. 2 is a block diagram illustrating the system ofFIG. 1 in greater detail. -
FIG. 3 is a flow diagram illustrating operation of dual charge intensifier pumps in the system ofFIGS. 1 and 2 . -
FIG. 4 is a flow diagram illustrating the operation of dual product intensifier sub-systems in the system ofFIGS. 1 and 2 . -
FIG. 5 is a cross-sectional diagram of a fluid processing device having an annular fluid flow channel for use with the system ofFIGS. 1 and 2 . -
FIG. 1 is a block diagram illustrating a multiple fluidproduct processing system 10 in accordance with an embodiment of this disclosure. In the example ofFIG. 1 ,system 10 includes dual intensifier sub-systems, each of which pressurizes a different fluid product for combination in a multi-stream fluid processing device. As shown inFIG. 1 ,system 10 includes acontroller 12, a firstfluid supply sub-system 14A, a secondfluid supply sub-system 14B, and afluid intensifier system 15.Controller 12 controls the operation offluid supply sub-systems fluid intensifier system 15 to produce high pressure streams of fluid for combination influid processing device 28. - Each
fluid sub-system respective fluid reservoir Reservoirs Supply pump 18A delivers fluid fromreservoir 16A, within one fluidproduct intensifier sub-system 17A, formed byreservoir 16A,supply pump 18A,charge intensifier 20A,product intensifier 22A andproduct intensifier 24A.Supply pump 18B delivers fluid fromreservoir 16B to another fluidproduct intensifier sub-system 17B, formed byreservoir 16B,supply pump 18B,charge intensifier 20B,product intensifier 22B, andproduct intensifier 24B.Controller 12 generates instructions to control the operation ofsupply pumps -
Charge intensifier pumps Product intensifier pumps product intensifier pumps Product intensifiers controller 12, to deliver a high pressure stream offluid 26A tofluid processing device 28. Likewise, in response tocontroller 12,product intensifiers fluid 26B tofluid processing device 28.Fluid processing device 28 receives the high pressure streams offluid fluid processing device 28 may include opposing, annular, coaxial flow paths, each of which carries one of the high pressure streams offluid fluid streams - As will be described,
system 10 may include various sensors, actuators, controllable valves and check valves to control flow and pressurization of fluid. In general,intensifier system 15 gains efficiencies through the use ofcharge intensifier pumps product intensifier pumps product intensifier pumps charge intensifier pump receiving product intensifier charge intensifier pump -
Product intensifier pumps controller 12 so that one is advancing (and hence delivering product) while the other is retracting and preloading. However, the retraction cycles of each set of product intensifier pumps 22A, 24A or 22B, 24B may at least partially overlap. During the retraction of aproduct intensifier pump intensifier sub-systems - As described in the above-referenced '134 patent, at the end of an advance cycle, fluid is allowed to enter
product intensifier pump charge intensifier pump 20A. The fluid is delivered at a relatively high pressure that is sufficient to cause a piston in theproduct intensifier pump charge intensifier pump 20A can increase the speed of the retraction stroke of theproduct intensifier pump charge intensifier pump 20A may have a larger product displacement per stroke than that of the product intensifier pumps 22A, 24A. Thus, thecharge intensifier pump 20A fully fills one of the product intensifier pumps 22A, 24A with each stroke. In addition, thecharge intensifier pump 20A fills the product intensifier pumps 22A, 24A without introducing air, thus aiding in the control and elimination of pulsation. - Even after fully retracting, fluid is still delivered from the
charge intensifier pump 20A to the barrel of one of the product intensifier pumps 22A, 24A, causing the fluid within the respective product intensifier pump to further increase in pressure. This reduces the amount of time theproduct intensifier pump product intensifier pump product intensifier pump charge intensifier pump 20A. In this manner, material is substantially constantly and consistently delivered by the product intensifier pumps 22A, 24A, which operate at least partially out of phase with one another. - The pistons in product intensifier pumps 22A, 24A are retracted quickly with the aid of the
charge intensifier pump 20A. The preload period is greatly reduced. Thus, efficiency is increased through a reduction in the required time duration for each cycle. Further, because thecharge intensifier pump 20A causes the retraction of each of the product intensifier pumps 22A, 24A, there is no need to provide a hydraulic retraction cycle for any of the product intensifier pumps. Rather, in some embodiments, the hardware and fittings necessary for delivery of working fluid for retraction can be eliminated. Thus, the complexity of the product intensifier pumps 22A, 24A is reduced, making them more efficient and cost effective.Charge intensifier pump 20B and product intensifier pumps 22B, 24B may operate in a substantially identical manner as that described above with respect to chargeintensifier pump 20A and product intensifier pumps 22A, 24A. - Combining charge intensifier pumps 20A, 20B and product intensifier pumps 22A, 24A, 22B, 24B in parallel enables delivery of multiple fluids to
fluid processing device 28 with precise pressure levels. The fluid products are delivered, separately, to two independent intermediate intensifier pumps that take advantage of hydraulic intensification to expel the products at high pressures to assure continuous product deployment in various systems. The separate products are delivered from the charge intensifier pumps 20A, 20B at pressures sufficient to increase the retract speed of the separate, product intensifier pumps 22A, 24A, 22B, 24B and fill the intensifier barrels with the two different fluids. - Charge intensifier pumps 20A, 20B ensure the filling of the product intensifier barrels without introduction of air. In addition, charge intensifier pumps 20A, 20B produce an elevated pressure in the separate product fluids within the product intensifier pumps 22A, 24A, 22B, 24B during the end of the retract cycle, thus reducing the amount of preload time required. The
product intensifiers -
Controller 12 processes sensor signals indicating the state or position of operation of eachcharge intensifier pump product intensifier pump controller 12 to determine the positions of each of the pistons in the product intensifier pumps 22A, 24A, 22B, 24B and the charge intensifier pumps 20A, 20B.Controller 12 actively controls the functioning of a number of valves located throughout the system, which may be referred to herein as “smart” valves. - An example of a suitable valve is disclosed in U.S. Pat. No. 6,328,542, issued Dec. 11, 2001, to Serafin et al., the entire content of which is incorporated herein by reference. Use of a smart valve is also described in the above-referenced '134 patent. In general, smart valves are actively controllable valves that can be opened and closed through the use of an actuator that is coupled with the
controller 12. The actuator may be an air cylinder, solenoid or other actuating mechanism.Controller 12 can determine, based on sensor data, when a particular intensifier pump is at or near the end of an extension or retraction cycle.Controller 12 can then control an actuator to open or close the appropriate smart valve or valves in anticipation of the completion of this cycle. -
FIG. 2 is a blockdiagram illustrating system 10 ofFIG. 1 in greater detail.FIG. 2 showscontroller 12,reservoirs fluid processing device 28, which may be a multi-stream annulus processor. In addition,FIG. 2 shows a pump (P1) 27 that delivers hydraulic working fluid to charge intensifier pumps 20A, 20B. In addition, pump 29 delivers hydraulic working fluid to product intensifier pumps 22A, 24A, and pump 31 delivers hydraulic working fluid to product intensifier pumps 22B, 24B.Controller 12 controls the operation ofpumps - Each intensifier pump 20, 22, 24 includes a working barrel and an intensifier barrel. For example,
charge intensifier pump 20A includes a largerdiameter working barrel 33A with a working piston, and a smallerdiameter intensifier barrel 35A with an intensifier piston. Thepiston 37A in workingbarrel 33A is driven forward by hydraulic fluid. In turn, the working piston drives the product piston inintensifier barrel 35A forward to expel product fluid. Similarly,product intensifier pump 24A includes a largerdiameter working barrel 33C with apiston 37C that is driven forward by hydraulic fluid. In turn, the working piston drives the product piston inintensifier barrel 35C ofproduct intensifier pump 24A forward to expelproduct fluid 26A at an elevated pressure for delivery tofluid processing device 28. Similar arrangements are provided for intensifier pumps 20B, 22A, 22B, 24B. - As further shown in
FIG. 2 , eachintensifier pump sensor 36 may be formed by a linear position transducer (LPT), linear variable displacement transducer (LVDT), limit switch, proximity switch, or other sensor capable of provide an indication of the position of the working piston tocontroller 12. In the example ofFIG. 2 ,system 10 also includes a set of actuators (A) 32A-32F and smart valves (SV) 30A-30F.Actuators 32 open and close respective smart valves 30, in response to control signals fromcontroller 12, to control flow of product fluid into the intensifier barrels of the respective intensifier pumps 20, 22, 24. - In addition, product intensifier pumps 22A, 24A, 22B, 24B each include a respective check valve (CV) 34A-34D between the output of the intensifier product barrel and
fluid processing device 28. EachCV 34A-34D is a passive one-way valve that prevents backflow into one pump (e.g., 22A) when the other pump (e.g., 22B) in the pair is expelling fluid at high pressure.Controller 12 receives sensor signals (S1-S6) fromsensors 36A-36F, as indicated byblock 36 inFIG. 2 . In response to the sensor signals,controller 12 generates control signals (A1-A6) to controlactuators 32A-32B and thereby control the operation of intensifier pumps 20, 22, 24, as indicated byblock 32. In particular,controller 12 controls the timing during which product fluid is introduced into the intensifier barrels of the intensifier pumps 20, 22, 24. -
Reservoirs reservoirs reservoirs reservoirs supply pump - Supply pump 18A feeds the first fluid product from
reservoir 16A tosmart valve 30A, which functions as a controllable check valve that can be actively opened and closed by anactuator 32A, under control bycontroller 12, as described above.Smart valves 30A-30F, actuators 32A-32F,sensors 36A-36F, pumps 27, 29, 31, andcontroller 12 collectively form a control system forfluid processing system 10.Smart valve 30A controls flow of product fluid into the intensifier barrel ofcharge intensifier pump 20A. Whensmart valve 30A is opened, the product fluid fromsupply pump 18A is allowed to fill theintensifier barrel 35A ofcharge intensifier pump 20A. Whensmart valve 30A is closed, the product fluid cannot enterintensifier barrel 35A. At the same time, whensmart valve 30A is closed, product fluid expelled fromintensifier barrel 35A cannot backflow through the smart valve. The product fluid is pressurized to a sufficient level to drive theintensifier piston 37A withincharge intensifier pump 20A backwards, such that theintensifier barrel 35A is filled with the product fluid. - Upon receiving the fluid, a piston within
charge intensifier pump 30A advances under hydraulic pressure produced bypump 27, expelling the product fluid at an intermediate pressure, e.g., in the range of approximately 700-2000 psi (approximately 4.8 megapascals to 13.8 megapascals). In particular, hydraulic fluid provided bypump 27 fills the workingbarrel 33A and drive the piston forward in theintensifier barrel 35A to expel the product fluid. At this point,smart valve 30A is closed and functions as a check valve to prevent backflow of product fluid towardsupply pump 18A. The product fluid is transmitted tosmart valves - Although the operation of
charge intensifier pump 18A has been described above,charge intensifier pump 18B may function in similar way. In particular,charge intensifier pump 18B receives product fluid inintensifier barrel 35B fromsupply pump 18B whencontroller 12 controls actuator 32B to opensmart valve 30B. Hydraulic fluid introduced into workingbarrel 33B bypump 27 drives thepiston 37B forward to expel the product fluid out ofintensifier barrel 35B at an increased pressure. Likecharge intensifier pump 20A,charge intensifier pump 20B transmits the resulting product fluid to a pair of product intensifier pumps, in this case product intensifier pumps 22B, 24B viasmart valves - In each case, the product fluid arriving at the respective product intensifier pumps 22A, 24A and 22B, 24B arrive at a substantially increased pressure relative to the pressure provided by
supply pumps charge intensifier pump charge intensifier pump actuator 32, under control bycontroller 12, preventing backflow of product fluid. -
Controller 12 determines whether to open and close the various smart valves 30 based on the positions of therespective pistons 37A-37F of the associated intensifier pumps 20, 22, 24.Sensors 36A-36F may be placed at the ends of the hydraulic pistons in charge intensifier pumps 20A, 20B and product intensifier pumps 22A, 24A, 22B, 24B,.or elsewhere, to sense the positions of the pistons and transmit the information tocontroller 12. Incharge intensifier pump 20A, for example, when the respective piston is at or near the end of a retraction cycle,controller 12 closessmart valve 30A to stop the fluid flow fromsupply pump 18A to thecharge intensifier barrel 35A. - At approximately the same time,
controller 12 controlshydraulic pump 27 to pump hydraulic fluid to workingbarrel 33A under pressure to drive the piston forward withinintensifier barrel 35A and thereby expel the fluid to one of the product intensifier pumps 22A, 24A. Product intensifier pumps 22A, 24A operate at least partially out of phase to receive product fluid at different times. Hence, thepiston 37D in firstproduct intensifier pump 22A is generally in a retracted position when thepiston 37C in secondproduct intensifier pump 24A is at or near the end of an extension cycle. Similarly, the-piston 37D inproduct intensifier pump 22A is in an extended position when thepiston 37C inproduct intensifier pump 24A is in a retracted position. To facilitate preloading, however, the retraction cycles of each pair of product intensifier pumps 22A, 24A or 22B, 24B may overlap for a limited period of time. - Product intensifier pumps 22B, 24B operate in a similar manner, providing out-of-phase intensification of product fluid received from
charge intensifier pump 20B. In this way, each pump in a respective pair of product intensifiers pumps 22A, 24A or 22B, 24B operates out of phase with the other pump in the pair to provide a combined output that is substantially continuous and constant. Product intensifier pumps 22A, 24A receive hydraulic working fluid within workingbarrels pump 29, while product intensifier pumps 22B, 24B receiving hydraulic workingbarrels pump 31.Controller 12 controls the operation ofpumps sensors 36A-36F, and also controlactuators 32A-32F in coordination withpumps smart valves 30A-30F. - Product intensifier pumps 22A, 24A, 22B, 24B may include substantially the same components as those of charge intensifier pumps 20A, 20B. For example, each
product intensifier pump respective piston 37C-37F that includes working surfaces within workingbarrel 33C-33F andintensifier barrel 35C-35F. In this manner, hydraulic fluid injected into workingbarrel 33C-33F drives the working surface of the piston forward to expel fluid fromintensifier barrel 35C-35F during an advance cycle. Similarly, injection of product fluid intointensifier barrel 35C-35F drives the working surface of the piston backwards during a retraction cycle. Eachpiston 37C-37F is described as a unitary piston having surfaces in the workingbarrel 33C-33F andintensifier barrel 35C-35F. In some embodiments, however, each piston may include a working piston in workingbarrel 33C-33F and a separate intensifier piston inintensifier barrel 35A-35F, and the working and intensifier pistons may be coupled together, e.g., by a rod or other coupling member. - A
sensor 36C-36F is mounted with eachproduct intensifier pump piston 37C-37F within the workingbarrel 33C-33F and/orintensifier barrel 35C-35F, and transmit the sensed position tocontroller 12. Again, eachsensor 36 may be formed by a linear position transducer (LPT), linear variable displacement transducer (LVDT), limit switch, proximity switch, or other sensor capable of providing an indication of the position of the piston tocontroller 12.Controller 12 uses the position information to actuate varioussmart valves 30C-30F viaactuators 32C-32F and control pumps 29, 30, 31, and thereby allow the pressurized product fluid to flow from the appropriatecharge intensifier pump product intensifier pump - With reference to a first pair of product intensifier pumps 22A, 24A, when
intensifier piston 37C inpump 24A reaches the end of its advance/extension cycle, information indicative of this position is sent by sensor (S) 36C tocontroller 12.Controller 12 then controlsactuator 32C to cause smart valve 30 to open. At the same time,controller 12 activates pump 27 to inject hydraulic working fluid into workingbarrel 33A ofcharge intensifier pump 20A, and controls actuator 32A to closesmart valve 30A, causing pressurized product fluid to be expelled fromintensifier barrel 35A and injected intointensifier barrel 35C ofproduct intensifier pump 24A. In response,piston 37C retracts. Whensensor 36C indicates thatpiston 37C has reached a point of full retraction,controller 12 delays the advance cycle for a short period of time to permit preloading of thepiston 37C.Controller 12 then activates pump 29 to inject hydraulic working fluid into workingbarrel 33C to drivepiston 37C forward. At the same time,controller 12 closessmart valve 30C. Aspiston 37C advances withinintensifier barrel 35C, fluid is expelled through one-way check valve (CV) 34A and intofluid processing device 28. - While
piston 37C ofproduct intensifier pump 24A is advancing,controller 12 actuatessmart valve 30D so thatintensifier barrel 35D ofproduct intensifier pump 22A is filled with product fluid fromcharge intensifier pump 20A, thereby retractingpiston 37D. Because the fluid is delivered at high pressure, e.g., at approximately 800-1200 psi,piston 37D is forced to retract backward at a relatively high speed, eliminating the need to provide a mechanism to hydraulically retract the piston. Oncepiston 37C has partially advanced andpiston 37D has fully retracted, as indicated byposition sensors controller 12 closessmart valve 30D and injects hydraulic working fluid into workingbarrel 33D to drivepiston 37D forward and thereby expel product fluid fromintensifier barrel 35D at a high pressure. The high pressure product fluid flows throughcheck value 34B tofluid processing device 28. Checkvalve 34A transmits flow in only one direction, towardfluid processing device 28, preventing backflow of pressurized fluid intoproduct intensifier pump 24A. -
Charge intensifiers product intensifiers charge intensifiers intensifier barrels 37C-37F with each respective advance stroke. In addition,charge intensifiers intensifier barrels 37C-37F without introducing air, thus aiding in the control and elimination of pulsation in the output flow. - As mentioned above,
controller 12 may be configured so that it does not immediately closesmart valve 30D upon full retraction ofpiston 37D ofintensifier pump 22A. Likewise,controller 12 may operate in the same way for intensifier pumps 24A, 22B, and 24B. Instead of immediately closing respectivesmart valves 30C-30F upon full retraction,controller 12 may allow the smart valves to remain open for a period of time to permit continued preloading. As the fluid continues to be delivered bycharge intensifier product intensifier barrel 35C-35F continues to increase, e.g., to approximately 1600-1700 psi (approximately 11.0 to 11.7 megapascals). At an appropriate time or set point,controller 12 then closes the respectivesmart valve 30C-30D to shut off the fluid supply, and prevent any backflow. Also, at about the same time that the smart valve is closed,controller 12 activates pump 29 or 31, as applicable, to supply hydraulic working fluid to the respectiveproduct intensifier pump respective piston 37C-37F to advance. - As
piston 37C-37F advances, it forces the fluid throughcheck valve 34A-34D at a very high pressure, e.g., approximately 40,000 psi (275 megapascals). As thepiston 37C-37F reaches the end of its extension cycle,controller 12 again openssmart valve 30C-30F and the process is repeated. Hence, the advance and retract cycles of each pair of charge intensifier pumps 20A, 20B, product intensifier pumps 22A, 24A and 22B, 24B operate generally out of phase with one another, but may have a slight overlap. For example,product intensifier pump 22A advances whileproduct intensifier pump 24A retracts, and vice versa. However, there may be a relatively short period during whichproduct intensifier pump 24A remains retracted whileproduct intensifier pump 22A begins to retract, providing a preloading interval. The alternating operation of the pumps in each pair of pumps may be similar to that described in the above-referenced '134 patent. - While
charge intensifier pump 20A is supplying fluid to the first pair of product intensifier pumps 22A, 24A, and those pumps are operating out-of-phase with one another to deliver highly pressurized product fluid tofluid processing device 28,charge intensifier pump 20B and the second pair of product intensifier pumps 22B, 24B are operating in the same manner. However, the intensifier sub-system formed bycharge intensifier pump 20A,product intensifier pump 22A, andproduct intensifier pump 24A delivers a different fluid than the intensifier sub-system formed bycharge intensifier pump 20B,product intensifier pump 22B, andproduct intensifier pump 24B. In this manner,system 10 supports supply of two different fluids tofluid processing device 28 for mixing, reacting, combining, or other processing of the fluids. In some embodiments,system 10 may include additional intensifier sub-systems similar or identical to those shown inFIG. 2 to deliver additional fluids such that the system can support processing of two or more fluids. In each manner, consistent delivery of multiple intensified product fluids can be achieved to support a variety of multiple fluid product stream applications. -
Controller 12 may be formed by a single centralized controller, or a plurality of parallel or distributed controllers. For example, in some embodiments, each intensifier pump may include its own controller, linked to a respective sensor and smart valve. For synchronized delivery, however, asingle controller 12 may be desirable.Controller 12 may be realized by any combination of one or more microprocessors, microcontrollers, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or the like, and may include hardware, software, firmware, or any combination of such components. -
Controller 12 controlssmart valves 30A-30C and pumps 27, 29, 31 in response to piston position signals provided bysensors 36A-36F to ensure precise and coordinated operation of the various intensifier pumps. In addition to position sensors,controller 12 also may receive sensed pressure levels from pressure sensors placed in various flow lines throughoutsystem 10. The pressure of the intensified fluids in the output lines leading tofluid processing device 28 may be in a range of approximately 5,500 to 40,000 psi (approximately 38 megapascals to 275 megapascals). Upon exitingfluid processing device 28, the fluid is then delivered downstream to be utilized in any appropriate process. For example, in the case of magnetic particle dispersions, the resulting fluid may be used to coat disk or tape media. -
Pump 27 may be selected to have sufficient power to inject hydraulic fluid into bothcharge intensifier pump 20A andcharge intensifier pump 20B at substantially the same time. In this manner, charge intensifier pumps 20A, 20B may advance and retract simultaneously to deliver pressurized product fluid at substantially the same time. In other embodiments, charge intensifier pumps 20A, 20B may operate out of phase with one another, such that oneintensifier pump barrels common pump 27 or two pumps operating in unison. -
Pumps product intensifier pump 22A retracts and preloads,product intensifier pump 24A advances, and vice versa, in response to fluid delivered bypump 29 and selective actuation ofsmart valves product intensifier pump 22B retracts and preloads,product intensifier pump 24B advances, and vice versa, in response to fluid delivered bypump 31 and selective actuation ofsmart valves - When
product intensifier pump 22A operates partially out of phase withproduct intensifier pump 24A, there also may be a slight overlap in the advancing cycle such that that is there is a short period in which both product intensifier pumps 22A, 24A are in the advancing cycle. For example, when theproduct intensifier pump 24A is near the end of the advancing phase or is almost fully extended,product intensifier pump 22A has already started to begin its advancing phase. This overlapping operation assures a consistent and uniform material output. Again, multiple hydraulic fluid pumps may be used to supply hydraulic fluid to each pair of product intensifier pumps 22A, 24A and 22B, 24B. However, a single pump for eachpump - In some embodiments, pumps 27, 29, 31 may be powered by a single, common electric motor. With the same single motor and single power source, pumps 27, 29, 31 may operate consistently without significant variation in energy/power fluctuation from pump to pump. Therefore, whether the system is used as a delivery system of multiple fluid streams or as a mixing system utilizing its high pressure and high velocity product outputs, the use of the single motor to power the hydraulic fluid pumps 27, 29, 31 contributes to substantially pulse-free operation.
-
FIG. 3 is a flow diagram illustrating operation of dual charge intensifier pumps 20A, 20B in thesystem 10 ofFIGS. 1 and 2 . As shown inFIG. 3 , upon initiation of multi-stream flow (40),controller 12 engagessupply pump 18A (42A) andsupply pump 18B (42B) to deliver product fluid to charge intensifier pumps 20A, 20B, respectively. Controller senses the positions of the pistons in charge intensifier pumps 20A, 20B (43A, 43B) via thevarious position sensors charge intensifier pump controller 12 closes the associatedsmart valve hydraulic fluid pump 27 to advance the piston in respective charge intensifier pump (46A, 46B). As the piston advances, the respectivecharge intensifier pump 20A, 2B delivers intensified fluid (48A, 48B). (00561 If the piston in thecharge intensifier pump controller 12 opens the pertinentsmart valve respective supply pump intensifier barrel charge intensifier pump controller 12 waits for a delay period (50A, 50B) to receive the next position indication fromsensors sensors smart valves pump 27 may be controlled on a coordinated or independent basis bycontroller 12. -
FIG. 4 is a flow diagram illustrating the operation of dual product intensifier sub-systems in thesystem 10 ofFIGS. 1 and 2 . As shown inFIG. 4 , controller senses the positions of pistons associated withproduct intensifier pump respective sensors 36C-36F. When a respective piston is fully extended,controller 12 opens a respective smart valve (62A, 76A, 62B, 76B), allowing the piston in the product intensifier pump to receive intensified product fluid fromcharge intensifier pump - When
controller 12 senses that the piston in a respectiveproduct intensifier pump charge intensifier pump product intensifier pump respective intensifier barrel 35C-35F increases, providing pre-loading. Alternatively,smart valves 30C-30F remains open until a predetermined pressure is measured, rather than waiting for a predetermined delay period. -
Controller 12 then controls pump 29 or 31, as applicable, to deliver hydraulic fluid to the respective workingbarrel 33C-33F, and thereby advances the piston to a preload position (68A, 82A, 68B, 82B). The piston then enters an extension cycle (70A, 84A, 70B, 84B) to advance the piston and thereby expel the intensified product fluid (72A, 86A, 72B, 86B) for delivery tofluid processing device 28. Charge intensifier pumps 22A, 24A generally perform the same functions, but at different times so that the two product intensifier pistons work together to achieve a smooth and continuous product outflow. Charge intensifier pumps 22B, 24B work in a similar manner. The process continues indefinitely under control ofcontroller 12 until a desired amount of the two or more fluids has been delivered tofluid processing device 28. - Exemplary characteristics of
fluid processing device 28 will now be described with reference toFIG. 5 .FIG. 5 is a cross-sectional diagram of afluid processing device 28 having an annular fluid flow channel for use with thesystem 10 ofFIGS. 1 and 2 . Thefluid processing device 28 ofFIG. 5 is an example of a multiple fluid product stream processing device suitable for use withsystem 10.Fluid processing device 28 may be similar to the device described in U.S. Pat. No. 6,923,213, the entire content of which is incorporated in this disclosure by reference. -
Fluid processing device 28 may be designed to handle pressurized fluids fromintensifier system 10, at a pressure up to or greater than approximately 40,000 psi (275 MPa). The first fluid fromsystem 10 entersprocessing device 28 throughfirst input 26A, and the second fluid fromsystem 10 enters the device throughsecond input 26B. The first fluid is contained withinflow channel 100 while the second fluid is contained withinflow channel 102.Flow channels annular flow channels flow path cylinder 108, which defines an annular flow channel for the first and second fluids. - The inner diameter of
flow path cylinder 108 defines an outer diameter ofannular flow channels cylinder 108.Rod 110 is positioned insideflow path cylinder 108, and defines first and second ends. A first end ofrod 110 extends intoannular flow channel 104 and a second end ofrod 110 extends into secondannular flow channel 106. Ordinarily,rod 110 may be concentric with theannular flow channels flow path cylinder 108. The outer diameter ofrod 110 defines the inner diameter ofannular flow channels channels annular flow channels flow path cylinder 108 androd 110. In some embodiments, the various flow paths and channels withindevice 28 may be machined using a common block of material. - The first fluid flows along
annular flow channel 104, e.g., from left to right inFIG. 5 , while the second fluid flows alongannular flow channel 106, e.g., from right to left inFIG. 5 . The two fluids collide at ornear outlet 112 formed inflow path cylinder 108, e.g., approximately at the lateral center ofcylinder 108.Outlet 112 is ported through the wall ofcylinder 108 at the midpoint along the length of the cylinder. The energy dissipation from the shear and extensional forces of the collision of the two fluids flowing alongannular flow channels - Additionally, the first fluid and the second fluid are mixed, reacted or combined to form a newly combined final fluid product. Moreover,
annular flow channels fluid processing device 28 by increasing surface area associated withflow channels fluid processing device 28 may be used to reduce the size dispersed phase, such as particles, in each of the two fluids. The final fluid product is expelled throughoutlet 112 and exitsfluid processing device 28 via an output line. - In some embodiments, high pressure fluid may be heated through a heater or cooled down from the intensifying process within
intensifier system 10 by a heat exchanger (not shown) prior to enteringprocessing device 28.Fluid processing device 28 may includepressure sensors fluid processing device 28, as well astemperature sensors output 112 may also be included (not shown).Sensors temperature sensors fluid processing device 28. -
Controller 12 may receive the pressure measurement and adjust the pressure of the fluids at first andsecond inputs fluid processing device 28. Alternatively, the controller may adjust the pressure of charge intensifier pumps 20A, 20B and/or bothproduct intensifiers controller 12 may receive temperature measurements, and cause adjustment of the temperature to one or more fluids, as needed, by changing the heater and/or heat exchanger settings to maintain a desired input temperature for each fluid entering thefluid processing device 28 in response to a desired output temperature atoutput 112. - Substantially identical flows of each fluid down their respective
annular flow channels controller 12 may sense parameters such as temperature or pressure and control the pressure of the fluids delivered into theannular flow channels -
Gland nuts flow path cylinder 108 in the proper location withinfluid processing device 28.Gland nuts FIG. 5 ) that allow fluid to flow freely throughflow channels annular flow channels Rod 110 may be cylindrically shaped, although the disclosure is not necessarily limited in that respect. For example, other shapes ofrod 110 may further enhance wall shear forces in the annular flow channels. Alternative shapes may include a circular cylinder, oval cylinder or polygon cylinder. -
Rod 110 may be free to move and vibrate within theflow path cylinder 108. In particular,rod 110 may be unsupported withinflow path cylinder 108. Free movement ofrod 110 relative to flowpath cylinder 108 may provide an automatic anti-clogging action tofluid processing device 28. If dispersed phase, such as particles or agglomerations, in one or both of the fluids become clogged insidefluid processing device 28, e.g., at the edges ofannular flow channels rod 110 may respond to local pressure imbalances by moving or vibrating. - For example, a clog within
cylinder 110 or in proximity ofannular flow channels rod 110 to move or vibrate. The movement and/or vibration ofrod 110, in turn, may help to clear the clog and return the pressure balance withinfluid processing device 28. In this manner, allowingrod 110 to be free to move and vibrate within theflow path cylinder 108 can facilitate automatic clog removal. In other embodiments,rod 110 may be fixed within fluid processing device 37. For example,rod 110 may be supported by struts, bearings, or the like. - To further improve clog removal, or permit clog removal when
rod 110 is fixedly mounted, a pulsated short term pressure increase in the input flow atfirst input 26A,second input 26B or both can be performed upon identifying a clog. For example, as mentioned above,temperature sensors output 112 may identify temperature changes inflow channels controller 12 may control pumps or smart valves insystem 10 to apply a short term pressure increase, e.g., a two-fold pressure increase for approximately a five-second duration, which may cause more substantial movement and/or vibration ofrod 110 to facilitate clog removal. - The pulsated short term pressure increase in one or both input flows may be performed in response to identifying a clogged condition, or on a periodic basis. For example, product intensifier pumps 22A, 24A, 22B, 24B and/or both charge intensifier pumps 20A, 20B may be controlled by
controller 12 to adjust the input pressure of the respective first or second fluids tofluid processing device 28. Alternatively,controller 12 may control inlet valves associated withdevice 28 the first and second fluids to selectively increase or decrease pressure and thereby unclogdevice 28. A short term pressure increase may be particularly useful in clearing clogs that affect bothannular flow channels annular flow channels - In different embodiments,
outlet 112 may have a fixed or adjustable size. For example,outlet 112 may take the form of a gap with an adjustable width. Flowpath cylinder 108 androd 110 may define substantially constant diameters. The components offluid processing device 28, includingflow path cylinder 108 androd 110 may be formed of a hard durable metallic material such as steel or a carbide material. As one example, flowpath cylinder 108 androd 110 may be formed of tungsten carbide containing approximately six percent tungsten by weight; - Various embodiments of the invention have been described. Although this disclosure generally describes an intensifier and processing system designed to accommodate two different fluid products, in other embodiments, the system may be adapted for multiple product streams, e.g., two, three or more fluid products. In particular, an intensifier sub-system as described herein may be replicated to provide an additional fluid product stream into a fluid processing device. In such an embodiment, two, three or more different product fluids may be directed at one another to achieve mixing, reaction, or combination of the fluids. These and other embodiments are within the scope of the following claims.
Claims (30)
1. A system comprising:
a first intensifier sub-system comprising a first charge intensifier pump, a first product intensifier pump that receives a first fluid from the first charge intensifier pump via a first controllable valve, a second product intensifier pump that receives the first fluid from the first charge intensifier pump via a second controllable valve;
a second intensifier sub-system comprising a second charge intensifier pump, a third product intensifier pump that receives a first fluid from the first charge intensifier pump via a third controllable valve, a fourth product intensifier pump that receives the first fluid from the first charge intensifier pump via a fourth controllable valve;
a controller that controls the controllable valves based on positions of pistons associated with the product intensifier pumps such that each of the controllable valves is open when the piston associated with the respective product intensifier pump is near an end of an extension cycle and closed when the piston associated with the respective product intensifier pump is at an end of a retraction cycle; and
a fluid processing device having a first input that receives the first fluid from the first and second product intensifier pumps, a second input receives the second fluid from the third and fourth product intensifier pumps, and an output that delivers a combined product of the first and second fluids.
2. The system of claim 1 , wherein the fluid processing device further comprises:
a first annular flow channel coupled to the first input that delivers the first fluid in a first direction; and
a second annular flow channel coupled to the second input channel that delivers the second fluid in a second direction opposing the first direction such that the first and second fluid collides and combine with one another.
3. The system of claim 2 , wherein the fluid processing device further comprises a flow path cylinder that defines an outer diameter of the first and second annular flow channels, the outlet being formed in the flow path cylinder, and a rod, positioned within the flow path cylinder, that defines an inner diameter of the first and second annular flow channels.
4. The system of claim 1 , further comprising a plurality of position sensors, each of the position sensors sensing the position of one of the pistons associated with one of the product intensifier pumps.
5. The system of claim 1 , further comprising a first hydraulic fluid pump that delivers hydraulic fluid to actuate the pistons in the first and second charge intensifier pumps.
6. The system of claim 5 , further comprising a second hydraulic fluid pump that delivers hydraulic fluid to actuate the pistons in the first and second product intensifier pumps, and a third hydraulic fluid pump that delivers hydraulic fluid to actuate the pistons in the third and fourth intensifier pumps.
7. The system of claim 6 , further comprising an electric motor that powers each of the first, second and third hydraulic pumps.
8. The system of claim 1 , wherein the first and second charge intensifier pumps deliver the respective first and second fluids at a pressure level in a range of approximately 800 to 1700 pounds per square inch (psi).
9. The system of claim 8 , wherein the product intensifier pumps deliver the respective first and second fluids at a pressure level in a range of approximately 5,500 to 40,000 psi.
10. The system of claim 1 , wherein the controller controls the controllable valves and one or more hydraulic pumps such that the first and second product intensifier pumps operate at least partially out of phase with one another, and such that the third and fourth product intensifier pumps operate at least partially out of phase with one another.
11. The system of claim 1 , wherein the first product intensifier pump retracts while the second product intensifier pump advances, and the third product intensifier pump retracts while the second product intensifier pump advances.
12. The system of claim 11 , wherein the controller controls the hydraulic pumps and the controllable valves so that the first product intensifier pump is near an end of the extension cycle when the second product intensifier pump is near an end of the retraction cycle, and so that the third product intensifier pump is near an end of the extension cycle when the fourth product intensifier pump is near an end of the extension cycle.
13. The system of claim 1 , wherein the first and second product intensifier pumps have extension cycles that at least partially overlap, and wherein the third and fourth product intensifier pumps have extension cycles that at least partially overlap.
14. The system of claim 1 , further comprising a first reservoir containing a supply of the first fluid, and a second reservoir containing a supply of the second fluid, wherein the first and second fluids are different.
15. The system of claim 14 , wherein the first and second fluids are selected from the group consisting of dissimilar liquids and liquid/solid mixtures.
16. A method comprising:
intensifying a first fluid via a first intensifier sub-system comprising a first charge intensifier pump, a first product intensifier pump that receives a first fluid from the first charge intensifier pump via a first controllable valve, a second product intensifier pump that receives the first fluid from the first charge intensifier pump via a second controllable valve;
intensifying a second fluid via a second intensifier sub-system comprising a second charge intensifier pump, a third product intensifier pump that receives a first fluid from the first charge intensifier pump via a third controllable valve, a fourth product intensifier pump that receives the first fluid from the first charge intensifier pump via a fourth controllable valve;
controlling the controllable valves based on positions of pistons associated with the product intensifier pumps such that each of the controllable valves is open when the piston associated with the respective product intensifier pump is near an end of an extension cycle and closed when the piston associated with the respective product intensifier pump is at an end of a retraction cycle; and
processing the first and second fluids in a fluid processing device having a first input that receives the first fluid from the first and second product intensifier pumps, a second input receives the second fluid from the third and fourth product intensifier pumps, and an output that delivers a combined product of the first and second fluids.
17. The method of claim 1 , wherein the fluid processing device further comprises:
a first annular flow channel coupled to the first input that delivers the first fluid in a first direction; and
a second annular flow channel coupled to the second input channel that delivers the second fluid in a second direction opposing the first direction such that the first and second fluid collide and combine with one another.
18. The method of claim 17 , wherein the fluid processing device further comprises a flow path cylinder that defines an outer diameter of the first and second annular flow channels, the outlet being formed in the flow path cylinder, and a rod, positioned within the flow path cylinder, that defines an inner diameter of the first and second annular flow channels.
19. The method of claim 16 , further comprising sensing the position of one of the pistons associated with one of the product intensifier pumps.
20. The method of claim 16 , further comprising delivering hydraulic fluid via a first hydraulic pump to actuate the pistons in the first and second charge intensifier pumps.
21. The method of claim 20 , further comprising delivering hydraulic fluid via a second hydraulic pump to actuate the pistons in the first and second product intensifier pumps, and delivering hydraulic fluid via a third hydraulic pump to actuate the pistons in the third and fourth intensifier pumps.
22. The method of claim 21 , further comprising using a single electric motor to power all of the first, second and third hydraulic pumps.
23. The method of claim 16 , wherein the first and second charge intensifier pumps deliver the respective first and second fluids at a pressure level in a range of approximately 800 to 1700 pounds per square inch (psi).
24. The method of claim 23 , wherein the product intensifier pumps deliver the respective first and second fluids at a pressure level in a range of approximately 5,500 to 40,000 psi.
25. The method of claim 16 , further comprising controlling the controllable valves and one or more hydraulic pumps such that the first and second product intensifier pumps operate at least partially out of phase with one another, and such that the third and fourth product intensifier pumps operate at least partially out of phase with one another.
26. The method of claim 16 , wherein the first product intensifier pump retracts while the second product intensifier pump advances, and the third product intensifier pump retracts while the second product intensifier pump advances.
27. The method of claim 26 , further comprising controlling the hydraulic pumps and the controllable valves so that the first product intensifier pump is near an end of the extension cycle when the second product intensifier pump is near an end of the retraction cycle, and so that the third product intensifier pump is near an end of the extension cycle when the fourth product intensifier pump is near an end of the extension cycle.
28. The method of claim 16 , wherein the first and second product intensifier pumps have extension cycles that at least partially overlap, and wherein the third and fourth product intensifier pumps have extension cycles that at least partially overlap.
29. The method of claim 1 , further comprising supplying the first fluid from a first reservoir, and supplying the second fluid from a second reservoir, wherein the first and second fluids are different.
30. The method of claim 29 , wherein the first and second fluids are selected from the group consisting of dissimilar liquids and liquid/solid mixtures.
Priority Applications (1)
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US11/583,761 US20080105316A1 (en) | 2006-10-18 | 2006-10-18 | Multiple fluid product stream processing |
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US11/583,761 US20080105316A1 (en) | 2006-10-18 | 2006-10-18 | Multiple fluid product stream processing |
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US11/583,761 Abandoned US20080105316A1 (en) | 2006-10-18 | 2006-10-18 | Multiple fluid product stream processing |
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